2004 Chevrolet Silverado 3500 problems, complaints & recalls
Most-reported problem areas: Service Brakes, Hydraulic (10) · Service Brakes (10) · Fuel System, Diesel (4)
🧭 Reliability snapshot
Compared against other Chevrolet Silverado 3500 model years — complaint volume vs the model's median year, recalls and severity. How we score →
🛣️ Complaints by mileage
35 NHTSA complaints that reported an odometer reading.
Safety recalls (0)
No recalls on record for this model year (campaigns announced since 2010).
Service bulletins (168)
Technical service bulletins are repair instructions manufacturers send dealers for known issues. Unlike recalls, the fix is not automatically free — but naming the bulletin at the service desk can save diagnosis time and support goodwill repairs.
Unknown Or Other 2025-07-18 · PIP5601C · Service Bulletin/Repair Instructions
this pi communicates the requirement to provide a pico file to receive diagnostic assistance from tac.
Unknown Or Other 2025-03-28 · 23-NA-001 · Service Bulletin/Repair Instructions
this service bulletin provides information for dealers/technicians on onstar module 2g sunset information.
Unknown Or Other 2025-02-20 · PIP5358D · Service Bulletin/Repair Instructions
this preliminary information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. technician should get record a sound clip or take a video of the noise for assessment by engineering. technician will need to
Engine 2024-12-18 · 03-06-01-023I · Service Bulletin/Repair Instructions
this service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
Engine 2024-10-07 · 03-06-01-023H · Service Bulletin/Repair Instructions
this service bulletin explains how to measure for oil consumption and possible reasons for loss of oil.
Unknown Or Other 2024-09-06 · PIT3271P · Service Bulletin/Repair Instructions
this preliminary information communication provides information to the technician about changing the tire and wheel size on vehicles. general motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. technician s
Showing the 6 most recent of 168 bulletins. Search all of them free at nhtsa.gov.
What owners report
2017-09-16 · Service Brakes · 104,000 mi“all factory hard brake lines have failed due to corrosion. i've replaced the intermediate line between the master cylinder and distribution block with stainless steel 1.5 yrs ago. i just replaced the rear brake lines along the axel. now the front brake lines have failed. in all cases the lines failed while driving and emptied the master cylinder. i…”
2016-11-22 · Service Brakes · 248,000 mi“brake line failure due to rusted & corroded brake lines resulting in costly repairs. luckily my 2004 chevy silverado 3500 was stationary when brake line ruptured and i was not towing a trailer or loaded with cargo at the time of failure. the abs pump also failed prior to line failure. my father in law had similar issues with the same model year 150…”
2016-03-14 · Service Brakes · 136,000 mi“2 problems: 1- while driving with no warning the brakes failed. after coasting to a stop i noticed a brake line had ruptured at the frame rail under driver area. i was able to crimp brake line with a pair of vice grip pliers and move truck to a safe location for repair. i believe the brake lines used on these trucks to be of such inferior qualit…”
2016-02-23 · Structure:body · 40,000 mi“tl* the contact owns a 2004 chevrolet silverado 3500. the contact stated that the rocker panels located under the doors on both the driver and passenger side of the vehicle were rusted and corroded. the vehicle was taken to the dealer who did not repair the vehicle. the contact indicated that the steel inside the rocker panel was not painted and co…”
2015-05-09 · Service Brakes · 103,000 mi · 💥 crash“front brake lines failed causing fluid loss and complete loss of brakes. happened at slow speed, but still was unable to stop before hitting a fixed object…”
2015-04-28 · Service Brakes · 100,000 mi“in march while driving my 2004 chevy 3500 diesel truck the brake warning lights inside the cab lit up and the brake pedal was feeling spongy. i took it into classic auto group mentor for service. a wheel bearing was replaced along with a few other items and i was told that it was good to go. i picked it up. the brake pedal was still spongy and the …”
2015-04-15 · Engine · 45,557 mi“ticking under hood. exhaust leak due to broken exhaust manifold bolt passenger side near firewall. tried to loosen other bolts, 3 more broke. truck has very low miles, 8.1l motor. internet shows thousands of same issues. bolts used are very thin for what they do. *tr…”
2015-03-23 · Fuel System, Gasoline“2004 chevrolet silverado 3500. consumer writes in regards to engine injectors issue. *smd the consumer stated the injectors were replaced in 2010, and now then need to be replaced again. …”
2013-09-18 · Service Brakes · 68,914 mi · 💥 crash“i was coming home from work this evening and was pulling up to the garage and the brakes failed causing me to hit the garage. i was traveling less than 5 mph. the brake pedal went all the way to the floor and the vehicle would not stop. after getting out of the vehicle found brake fluid all over the driveway. brake lines was found to be rusted in t…”
2013-08-29 · Service Brakes · 74,000 mi“had just hooked up our 38' - 12,000lb fifth wheel and headed out for the weekend. came to the first stop sign and the brake pedal went to the floor. luckily got stopped with trailer brakes. after stopping, pumping brakes caused brake fluid to pour out from just in front of the driver's side rear wheel. upon research when we arrived home, i find tha…”
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.